INSTALLATION INSTRUCTIONS

DeltaVTM Type KJ7000 Series Zone 1 I/O System

Emerson Process Management

12P3292 Rev. C
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CONTENTS
1. Scope.................................................................................................................................... 3
2. Product Description .............................................................................................................. 3
2.1 Carrier: KJ7001X1-BA1................................................................................................. 4
2.1.1 Locating and Mounting of Carrier........................................................................ 6
2.1.2 Card Mounting and Keying.................................................................................. 7
2.2 Power Supply: KJ7011X1-BA1 .................................................................................... 8
2.3 CPU Card: KJ7012X1-BA1 .......................................................................................... 8
2.4 I/O Cards ...................................................................................................................... 9
2.4.1 Field Wiring Screw Terminal Definition .............................................................. 11
2.4.2 Intrinsic Safety of I/O Channels.......................................................................... 12
3. FM Installation Figure ........................................................................................................... 13
4. Cleaning and Inspection ....................................................................................................... 14

2001 2005 Fisher-Rosemount Systems, Inc. All Rights Reserved.

DeltaV and the DeltaV design are marks of one of the Emerson Process Management group of
companies. All other marks are the property of their respective owners.
Emerson Process Management Distribution Ltd. Process Systems and Solutions,
Meridian South
Meridian Business Park
Leicester, UK LE19 1WY

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1. SCOPE
TM
This document provides the guidelines for the installation of the DeltaV Zone 1 I/O System in locations
with explosive atmospheres.
ATEX - Zone 1 or Zone 2 (ATEX Marking: II 2 G (1)GD EEx de [ia] IIC T4).
FM - Class I, II, III, Division 2, Groups A, B, C, D, F, G Hazardous Locations with Class I, II, III,
Division 1, Groups A, B, C, D, E, F, G Intrinsically Safe Field Circuits, Temperature Code T4 and
Class I, Zone 1 or Zone 2, Group IIA, IIB, IIC Hazardous Locations with Class I, Zone 0 Field
Circuits [AEx ia] IIC, Temperature Code T4.

Installation shall be in accordance with:

ATEX - EN 60079-14.
FM - National Electrical Code , NFPA 70, Article 504 or 505 and ANSI / ISA-RP 12.6.
Any state-specific regulations.

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WARNING: The System must not be connected to any device that uses or generates in excess of
250 Vrms or DC.
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WARNING: Substitution of components may impair intrinsic safety.

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2. PRODUCT DESCRIPTION
The Zone 1 I/O System is a process control subsystem with explosion protection features. This system
has intrinsically safe field wiring connections and can be mounted in:
ATEX - Zone 1 or Zone 2 locations.
FM - Class 1 Division 2, or Class 1 Zone 1 or Zone 2 locations. (See Section 3. FM
INSTALLATION FIGURE).
The operating ambient temperature range for the system is -20 to 70 degrees C.
The system consists of a Carrier, a Power Supply card, a CPU card, and various I/O interface cards. The
system is designed to only support vertical mounting as shown in figure 1.

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Figure 1. Zone 1 I/O System

2.1 Carrier: KJ7001X1-BA1

The Carrier is a panel mounted assembly that provides the mounting and connection for the Power
Supply, CPU, and up to four I/O cards. Four mounting holes allow for the panel mounting. The Carrier
also provides the screw terminals for:
Connecting input power (+24 VDC) and Earth Ground (3 screw terminals).
An optional RS485 communications port to the CPU card (5 screw terminals).
I/O Card intrinsically safe field wiring connections (192 screw terminals).

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Three warning labels are mounted on the Carrier (see Figure 1). Each is written in English, German, and
French.
Warning Label #1(located on hinged cover over input power and RS485 port screw terminals):
DO NOT OPEN WHILE ENERGIZED
Warning Label #2 (located on right side of carrier): CLEAN ONLY WITH DAMP CLOTH
Warning Label #3 (located on right side of carrier): AFTER SWITCH OFF WAIT 1 MINUTE
BEFORE PLUGGING OR UNPLUGGING CARDS
A hinged cover protects the connections for the input power (+24 VDC) and the RS485 port.

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WARNING: In hazardous locations do not open cover while system is energized.

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Input power (+24 VDC) should be connected to the screw terminals labeled +24V and Return. Earth
Ground must be connected to the terminal labeled with the ground symbol. The optional RS485 port
provides an isolated RS485 communications port.

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WARNING: The input power connections and RS485 port connections are not intrinsically safe and
should not be connected or disconnected in hazardous locations unless the connections have been de-
energized.
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Four groups of 48 screw terminals are located along the top and bottom of the carrier. Each group
consists of two rows of terminals. The terminals are labeled 1 through 48, with the taller height row being
odd numbers (1, 3, 5 47) and the shorter height row being the even numbers (2, 4, 6 48). Each
group provides the field wiring connections (I/O channels) for one of the four I/O Card locations:
I/O Card Slot 1 Screw Terminals Bottom left.
I/O Card Slot 2 Screw Terminals Bottom right.
I/O Card Slot 3 Screw Terminals Top left.
I/O Card Slot 4 Screw Terminals Top right.
Refer to I/O card information in Section 2.4.1 to determine specific screw terminal definition for each I/O
card type.

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2.1.1 Locating and Mounting of Carrier

The Carrier shall be mounted vertically (screw terminals for cards 3 and 4 at the top). Additionally,
mounting shall allow sufficient natural airflow.
See Figure 2 for the dimensions of the carrier. Note also the location of the four keys associated with the
four I/O card slots. These are labeled A, B, C, and D and are described further in Section 2.1.2.

350.00 mm
1 (13.78 in.)
10.00 cm
300.00 mm 35.76 mm
(3.9 in.) (1.40 in.)
(11.81 in.)

05.00 mm
(0.19 in.) A A A A

B B B B

PS CPU 1 2 3 4

C C C C

D D D D

1 Notes:
10.00 cm 1 Clearance recommended for field wiring
(3.9 in.)

Figure 2. Carrier Dimensions

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In hazardous locations the system must be mounted in an appropriate enclosure. The following table lists
the enclosure requirements for the various installation environments.

Installation Environment Requirements

ATEX Zone 1 Per EN50019:2000 (or later)

ATEX Zone 2 Per EN50021:1999 or EN60079-15:2003 (or later)

FM Class I, Division 2 Nema 4

FM Class I, Zone 1 Housing with Power Interlock Switch R. STAHL

Fieldstation Enclosure, Model 8125/5***-2*-KJ7000

FM Class I, Zone 2 Nema 4

Safe Areas No Special Requirements

For installations in hazardous locations endangered by dust the system must be mounted in an
appropriate enclosure certified for the location.

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WARNING: To avoid electrostatic charges, assure the metal plate (on the back of the carrier) is
electrically connected to the potential equalizing system within the hazardous area.

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2.1.2 Card Mounting and Keying

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WARNING: In hazardous locations the Power Supply, CPU, and I/O Cards should not be removed
from or inserted into the Carrier unless the input power supply has been de-energized for 1-minute
minimum.
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The Power Supply Card installs in the left most slot (labeled PS) and the CPU Card installs in the
adjacent slot (labeled CPU). These Carrier slots are keyed at the factory to only allow these cards to be
inserted.
The remaining four card slots (labeled 1, 2, 3, and 4) are used for the I/O Cards (see Figure 2).
Each slot has four keys that are used to configure the slot to only allow a specific I/O card type to be
inserted. The keys are labeled A, B, C, and D on the carrier. Each I/O card type requires that two
keys be removed. The keys are removed by breaking them off using a standard screwdriver. Refer to
information of the I/O cards (Section 2.4) to determine the key codes associated with each card type.

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A key replacement kit is included with each carrier to allow for reconfiguring the I/O Card slots. This kit
consists of eight replacement keys. These replacement keys can be inserted into a key location in which
the key has previously been removed.
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WARNING: If the I/O card type is changing, the slot keying must be reconfigured. Additionally, the
field wiring must be changed so the entity parameters of the field circuits match those of the new I/O card
being installed.
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All cards are secured to the carrier using two hex socket-head screws. These screws require a 3mm hex
head wrench (or driver).

2.2 Power Supply: KJ7011X1-BA1

The Power Supply card installs in a dedicated slot in the Carrier (labeled PS) and utilizes the +24 VDC
input power to generate isolated power (+26 VDC and +8VDC) for the CPU and I/O cards.

2.3 CPU Card: KJ7012X1-BA1

The CPU card installs in a dedicated slot in the Carrier (labeled CPU) and provides the
scanner/controller functionality for the system. It communicates with the I/O cards over a dedicated
communications bus on the Carrier. It also communicates to a workstation over redundant 100M Fiber
ethernet ports. Additionally, the CPU card generates the +5 VDC for the system.
The 100M Fiber Ethernet ports utilize MT-RJ style connectors. These ports are energy limited to allow
them to be utilized in Zone 1 environments.

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WARNING: In Zone 1 environments, any devices that connect to the fiber cables must also limit the
fiber energy and be certified accordingly. Emerson Process Management offers a Fiber Switch with the
required certifications.
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WARNING: Laser radiation can be emitted from fiber optic connectors and cables. Looking directly
at the laser beam can cause eye injuries. Never look directly into the laser beam.
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2.4 I/O Cards

The I/O Cards are installed in the four I/O card slots in the Carrier and provide intrinsically safe interfaces
to various channel types.
The following table provides details on the I/O Card types.

I/O CARD TYPE CARRIER CHANNEL STYLE / TYPICAL

NUMBER KEYS NUMBER OF APPLICATION
REMOVED CHANNELS

Discrete I/O KJ7101X1-BA1 B and D Discrete Input: NAMUR Proximity

- Dry Contact Switch
- 16 Channels Dry Contact
Optocoupler
Discrete Output: Ex i Solenoid
- High Side DC Valve
- 8 Channels Ex i Indicating
Lamp

Analog I/O KJ7102X1-BA1 A and C Analog Input: 2-Wire

- 2-Wire 4 to 20 Transmitters (with
mA with HART or without HART)
- 8 Channels
Analog Output; Valve Positioners
- 4-20 mA with and I/P
HART Converters (with
or without HART)
- 4 Channels

Fieldbus H1 KJ7103X1-BA1 B and C H1 Interface, 2 Ports H1 Segments,

FISCO
H1 Segments,
non-FISCO

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The following table lists the entity parameters for the I/O Cards and their channel types. This defines the
loads that can be connected to each terminal pair.

I/O CARD CHAN-

NEL ENTITY PARAMETERS
TYPE
ATEX ATEX ATEX FM FM FM
Group IIC Group IIB Group IIA Groups A, B Group C Group D

Discrete I/O Discrete Uo = 10 V Uo = 10 V Uo = 10 V Voc = 10 V Voc = 10 V Voc = 10 V

(KJ7101X1- Input Io = 10 mA Io = 10 mA Io = 10 mA Isc = 10 mA Isc = 10 mA Isc = 10 mA
BA1) Po = 25 mW Po = 25 mW Po = 25 mW Po = 25 mW Po = 25 mW Po = 25 mW
Co = 3 uF Co = 20 uF Co = 100 uF Ca = 3 uF Ca = 20 uF Ca = 100 uF
Lo = 350 mH Lo = 1000 mH Lo = 1000 mH La = 350 mH La = 1000 mH La = 1000 mH
Discrete Uo = 27.4 V Uo = 27.4 V Uo = 27.4 V Voc = 27.4 V Voc = 27.4 V Voc = 27.4 V
Output Io = 90 mA Io = 90 mA Io = 90 mA Isc = 90 mA Isc = 90 mA Isc = 90 mA
Po = 0.6 W Po = 0.6 W Po = 0.6 W Po = 0.6 W Po = 0.6 W Po = 0.6 W
Co = 86 nF Co = 676 nF Co = 2.26 uF Ca = 86 nF Ca = 676 nF Ca = 2.26 uF
Lo = 4.3 mH Lo = 17 mH Lo = 34 mH La = 4.3 mH La = 17 mH La = 34 mH

Analog I/O Analog Uo = 27.4 V Uo = 27.4 V Uo = 27.4 V Voc = 27.4 V Voc = 27.4 V Voc = 27.4 V
(KJ7102X1- Input Io = 93 mA Io = 93 mA Io = 93 mA Isc = 93 mA Isc = 93 mA Isc = 93 mA
BA1) Po = 0.6 W Po = 0.6 W Po = 0.6 W Po = 0.6 W Po = 0.6 W Po = 0.6 W
Co = 86 nF Co = 676 nF Co = 2.26 uF Ca = 86 nF Ca = 676 nF Ca = 2.26 uF
Lo = 4.1 mH Lo = 16 mH Lo = 31 mH La = 4.1 mH La = 17 mH La = 34 mH
Analog Uo = 27.4 V Uo = 27.4 V Uo = 27.4 V Voc = 27.4 V Voc = 27.4 V Voc = 27.4 V
Output Io = 89 mA Io = 89 mA Io = 89 mA Isc = 89 mA Isc = 89 mA Isc = 89 mA
Po = 0.6 W Po = 0.6 W Po = 0.6 W Po = 0.6 W Po = 0.6 W Po = 0.6 W
Co = 86 nF Co = 676 nF Co = 2.26 uF Ca = 86 nF Ca = 676 nF Ca = 2.26 uF
Lo = 4.4 mH Lo = 17 mH Lo = 34 mH La = 4.4 mH La = 17 mH La = 34 mH

Fieldbus H1 FISCO Ui = 17.5 V Ui = 17.5 V Ui = 17.5 V Vmax = 17.5V Vmax = 17.5V Vmax = 17.5V
(KJ7103X1- Ii = 380 mA Ii = 380 mA Ii = 380 mA Imax = 380mA Imax = 380mA Imax = 380mA
BA1) Pi = 5.32 W Pi = 5.32 W Pi = 5.32 W Pi = 5.32W Pi = 5.32W Pi = 5.32W
Ci = 0 uF Ci = 0 uF Ci = 0 uF Ci = 0 uF Ci = 0 uF Ci = 0 uF
Li = 0 uH Li = 0 uH Li = 0 uH Li = 0 uH Li = 0 uH Li = 0 uH
Non- Ui = 30 V Ui = 30 V Ui = 30 V Vmax = 30 V Vmax = 30 V Vmax = 30 V
FISCO Ii = Any Ii = Any Ii = Any Imax = Any Imax = Any Imax = Any
Pi = Any Pi = Any Pi = Any Pi = Any Pi = Any Pi = Any
Ci = 0 uF Ci = 0 uF Ci = 0 uF Ci = 0 uF Ci = 0 uF Ci = 0 uF
Li = 0 uH Li = 0 uH Li = 0 uH Li = 0 uH Li = 0 uH Li = 0 uH

For installation in hazardous areas endangered by dust, the system must be mounted in an appropriate
housing certified for the location.
The field circuits can also be extended into hazardous areas endangered by dust. These circuits must
connect to equipment approved for such applications. Only the U/V, I, and P parameters in the above
table apply to dust atmospheres.

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2.4.1 Field Wiring Screw Terminal Definition

The field wiring screw terminals for each I/O Card consist of 48 screw terminals (located on the Carrier
see Section 2.1). The terminals are labeled 1 through 48, with the taller height row being odd numbers
(1, 3, 5 47) and the shorter height row being the even numbers (2, 4, 6 48). The following table
details the I/O Channel screw terminal relationship for each I/O Card type.

SCREW TERMINAL # DISCRETE I/O ANALOG I/O FIELDBUS H1

KJ7101X1-BA1 KJ7102X1-BA1 KJ7103X1-BA1
1 DIN Channel 1 + AIN Channel 1 + H1 Port #1 +
2 DIN Channel 1 -
3 DIN Channel 2 + AIN Channel 1 - H1 Port #1 -
4 DIN Channel 2 -
5 DIN Channel 3 + AIN Channel 2 +
6 DIN Channel 3 -
7 DIN Channel 4 + AIN Channel 2 -
8 DIN Channel 4 -
9 DIN Channel 5 + AIN Channel 3 + H1 Port #2 +
10 DIN Channel 5 -
11 DIN Channel 6 + AIN Channel 3 - H1 Port #2 -
12 DIN Channel 6 -
13 DIN Channel 7 + AIN Channel 4 +
14 DIN Channel 7 -
15 DIN Channel 8 + AIN Channel 4 -
16 DIN Channel 8 -
17 DIN Channel 9 + AIN Channel 5 +
18 DIN Channel 9 -
19 DIN Channel 10 + AIN Channel 5 -
20 DIN Channel 10 -
21 DIN Channel 11 + AIN Channel 6 +
22 DIN Channel 11 -
23 DIN Channel 12 + AIN Channel 6 -
24 DIN Channel 12 -
25 DIN Channel 13 + AIN Channel 7 +
26 DIN Channel 13 -
27 DIN Channel 14 + AIN Channel 7 -
28 DIN Channel 14 -
29 DIN Channel 15 + AIN Channel 8 +
30 DIN Channel 15 -
31 DIN Channel 16 + AIN Channel 8 -
32 DIN Channel 16 -
33 DOUT Channel 1 + AOUT Channel 1 +

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34 DOUT Channel 1 - AOUT Channel 1 -

35 DOUT Channel 2 + AOUT Channel 2 +
36 DOUT Channel 2 - AOUT Channel 2 -
37 DOUT Channel 3 + AOUT Channel 3 +
38 DOUT Channel 3 - AOUT Channel 3 -
39 DOUT Channel 4 + AOUT Channel 4 +
40 DOUT Channel 4 - AOUT Channel 4 -
41 DOUT Channel 5 +
42 DOUT Channel 5 -
43 DOUT Channel 6 +
44 DOUT Channel 6 -
45 DOUT Channel 7 +
46 DOUT Channel 7 -
47 DOUT Channel 8 +
48 DOUT Channel 8 -

2.4.2 Intrinsic Safety of I/O Channels

The intrinsic safety of the I/O channels must be implemented for each field circuit in compliance with the
regulations specified by the applicable standards for engineering, selection and installation. A basic,
intrinsically safe circuit is created by the connection of a field device to the input or output of an I/O card in
accordance with the following criteria.

ATEX: Uo Field Device Ui

Io Field Device Ii
Po Field Device Pi
Co Field Device Ci + Capacitance of Cable
Lo Field Device Li + Inductance of Cable

FM: Voc Field Device Vmax

Isc Field Device Imax
Po Field Device Pi
Ca Field Device Ci + Capacitance of Cable
La Field Device Li + Inductance of Cable

Note that although some of the I/O Channel circuits utilize the common return of the system, the field
wiring installation must provide a separate return for each channel meeting separation requirements for
different I.S. circuits.

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3. FM INSTALLATION FIGURE

TRL Approved
P Intrinsically Safe
o
w Equipment
Note 1 I I I I
Note 2 e C O O O O
r P (For Entity
U C C C C Parameters see
S a a a a Section 2.4)
u r r r r
C d d d d
a p
r p
r l
i y
e
r

Fiber
Optic
Cables

Hazardous (Classified) Location: Hazardous (Classified)

Location:
- Class I, II, III, Division 2,
Groups A,B,C,D,F,G - Class I, II, III, Division
1, Groups A,B,C,D,E,F,G
- Class I, Zone 1 or Zone 2,
Groups IIA, IIB, IIC - Class I, Zone 0 or Zone 1,
Groups IIA, IIB, IIC

NOTES:
1. +24VDC (-15/+20%) input power at 3 Amps maximum. This voltage source must not generate or
contain in either normal or abnormal operation a source of potential in excess of 250Vrms or DC.
2. RS485 port connections. Equipment connected to this port must not generate or contain in either
normal or abnormal operation, a source of potential in excess of 250Vrms or DC.
3. The four I/O Card slots can be configured for various I/O card types. Refer to section 2.4 for details
of the cards, their channel types, and their entity parameters.
4. An appropriate enclosure is required to house the system. Refer to the table in section 2.1.1 for
enclosure requirements.

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4. INSPECTION AND CLEANING

During function inspections, comply with the guidelines set out in EN 60 079-17. This standard contains
the regulations of the international standard IEC 60 079-17.
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WARNING: Plastic components can become electrostatically charged during cleaning. In

hazardous locations this may pose a hazard. Only clean modules with a damp cloth.
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DeltaVTM Type KJ7000 Series Zone 1 I/O System Installation Instructions